Residual stress constrained self-support topology optimization for metal additive manufacturing

Xu, Shuzhi; Liu, Ji‐Kai; Ma, Yongsheng

doi:10.1016/j.cma.2021.114380

Cited by 50 publications

(14 citation statements)

References 33 publications

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“…A more refined and time consuming strategy could exploit a topology optimization analysis that takes into account even a manufacturability optimization, such as a reduction of the internal stresses that arise during fabrication. Interesting approaches that have been presented at the state of the art on this topic are described in [7], [8].…”

Section: Results and Conclusionmentioning

confidence: 99%

Topology Optimization of Static Turbomachinery Components

Meli¹,

Secciani²,

Ridolfi³

et al. 2023

Manufacturing Technology

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Additive Manufacturing has enabled the design of complex components in several technical fields. Considering turbomachinery components, additive manufacturing has unlocked the achievement of significant performances for dynamic rotoring components. The application of topology optimization methods is one of the main factors accelerating the technological development of this sector. This paper presents a procedure for the optimization of static turbomachinery components. The framework proposed compares the results obtained by introducing a lattice structure and a solid optimized shape. The procedure is presented with reference to a specific case study. To validate the proposed framework, the complete re-design of a thrust collar of a major Italian-based Oil&Gas company is carried out, demonstrating that the re-thinking of the component in terms of Topology Optimization is a straightforward approach to increase the overall performance of the produced part.

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Section: Results and Conclusionmentioning

confidence: 99%

Topology Optimization of Static Turbomachinery Components

Meli¹,

Secciani²,

Ridolfi³

et al. 2023

Manufacturing Technology

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“…To improve the comprehensiveness of design optimization, the concept of DfAM needs to be introduced. DfAM is proposed to take full advantage of the manufacturing capacity to achieve better performance while meeting the requirements of AM, which requires the designers to add AM direction, support structures, size limitations, and so on, as the design constraints [34][35][36]. For instance, Biedermann et al [37] proposed a CAD-based design method for AM flow channels to meet the AM overhang constraint.…”

Section: Am In the Fabrication Of Optimized Flow Channelsmentioning

confidence: 99%

Intelligent Design Optimization System for Additively Manufactured Flow Channels Based on Fluid–Structure Interaction

Zou

et al. 2022

Micromachines

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Based on expert system theory and fluid–structure interaction (FSI), this paper suggests an intelligent design optimization system to derive the optimal shape of both the fluid and solid domain of flow channels. A parametric modeling scheme of flow channels is developed by design for additive manufacturing (DfAM). By changing design parameters, a series of flow channel models can be obtained. According to the design characteristics, the system can intelligently allocate suitable computational models to compute the flow field of a specific model. The pressure-based normal stress is abstracted from the results and transmitted to the solid region by the fluid–structure (FS) interface to analyze the strength of the structure. The design space is obtained by investigating the simulation results with the metamodeling method, which is further applied for pursuing design objectives under constraints. Finally, the improved design is derived by gradient-based optimization. This system can improve the accuracy of the FSI simulation and the efficiency of the optimization process. The design optimization of a flow channel in a simplified hydraulic manifold is applied as the case study to validate the feasibility of the proposed system.

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“…The layer-by-layer material deposition or solidification process eliminates the barriers in fabricating complex structures, and meanwhile, boosts the design activities that lead to a number of superior-performing mechanical structure examples [1][2][3]. On the other hand, this novel processing method has its limitations and challenges to design activities, such as material anisotropy [4,5], overhang free issue [6,7], residual stress [8,9], porous structures [10,11], multiscale design [12][13][14], etc. Among these topics, material anisotropy, as an inevitable AM feature, has been extensively studied for a long time.…”

Section: Introductionmentioning

confidence: 99%

Concurrent Topological Structure and Cross-Infill Angle Optimization for Material Extrusion Polymer Additive Manufacturing with Microstructure Modeling

2022

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This paper contributes a concurrent topological structure and cross-infill angle optimization method for material extrusion type additive manufacturing (AM). This method features in modeling the process-induced material anisotropy through microscopic geometric modeling obtained by scanning electron micrographs. Numerical homogenization is performed to evaluate the equivalent effective properties of the 100-percentage cross-infilled local microstructures, and by introducing fitting functions, the relationship between equivalent effective material properties and varying cross-infill angles is empirically constructed. Then, optimization problems involving cross-infill angles as design variables are formulated, including concurrent optimization formulation. Numerical and experimental studies are conducted to illustrate the effectiveness of the proposed method. Both the numerical and experimental results demonstrate that the structural stiffness obtained by our proposed method has evidently improved.

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Residual stress constrained self-support topology optimization for metal additive manufacturing

Cited by 50 publications

References 33 publications

Topology Optimization of Static Turbomachinery Components

Topology Optimization of Static Turbomachinery Components

Intelligent Design Optimization System for Additively Manufactured Flow Channels Based on Fluid–Structure Interaction

Concurrent Topological Structure and Cross-Infill Angle Optimization for Material Extrusion Polymer Additive Manufacturing with Microstructure Modeling

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